Optimized Thickeners in Coal Preparation Plants

8/19/2019 Optimized Thickeners in Coal Preparation Plants

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Optimized thickeners in coal preparation plants

Using optimized thickeners for level measurement applications in a coal mind can yield safer and

more efficient plant control.

Level measurement equipment is part of almost every process in a coal mine. You hardly see the

instruments but they are there and make a huge difference when it comes to efficiency, safety and

automated control of the plant.Optimizirano thickeners u ugljenu pripreme postrojenja

Korištenje thickeners optimiziran za mjerenje nivoa aplikacije u ugljena um može prinosa i sigurnijeučinkovitiju kontrolu postrojenja.

Razina mjerne opreme je dio gotovo svakog procesa u rudarstvu. Vi jedva vidiinstrumenti, ali oni su tamo i čine veliku razliku kad je riječ o efikasnosti, sigurnosti iautomatska kontrola postrojenja.


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All mining concentrators and coal preparation plants have tailings thickeners. These instruments treat the

process water by removing suspended solids and then returning the water back to the concentrator or

coal prep plant. They then pump the solids to a tailings dam.

ve rudarstvo Koncentratori i pripreme uglja !iljke imaju pljeva thickeners. Ovi instrumenti goz!a potrošne vode putem uklanjanja suspendirane tvari, a zatim se vra"aju vodu natrag u koncentrator iliugljen prep !iljka. Oni su zatim pumpa solids da pljeva !rana.


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Reliable bed levels

Most tailings thickeners do not run efficiently because of a number of factors including:

1. The thickener does not have a reliable bed level interface transmitter that will work under all

environmental settling conditions and is not affected by density change; and

2. The thickener does not have turbidity or a suspended solids transmitter that will provide feedback to

the control room operator on how the flocculent dosing system is working.

By not utilizing a bed level transmitter that is affected by density, tailings thickener bed level are generally

run too low in the cone of the thickener reducing the underflow density that is pumped to the tailings damand also pumping too much water in the tailings.

The net effect is that the tailings dams will fill in volume faster, and there ill be an additional cost of

pumping the water back from the tailings dam to the concentrate or prep plant.

Most tailings thickeners utilize an automatic flocculent dosing system that takes samples of feed well

water and carries out an automatic jar settling test. This is so important where multiple coal/ore types are

processed through the plant because of different settling rates and characteristics. However, the

observers or clarometers floc batch systems fail from time to time and the tailings thickener can change

very quickly to not settling out the suspended solids.

The clarity output from higher end transmitters can alarm this condition to the operator in the controlroom. Some even have a ‘hindered layer’ output that can also be used in the control loop for the floc

dosing system as a back up. The use of a bed level transmitter will allow the tailings thickener to be run

automatically in conjunction with the underflow density transmitter and torque amps from the scraper.

This can:

1. Reduce costs in chemicals, broad spectrum floc dosing/coagulant dosing;

2. Return water pumping costs from the tailings dam;

3. Reduce tailings volume to the tailings dam; and

4. Increase the quality and volume of water returned to the concentrator from the thickener.

High powered sonar transducer

Hawk has developed a high powered range of multiple crystal array sonar transducers that have the

capability of operating and penetrating suspended solids to give reliable performance measuring the

heavy density BED level.


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#ouzdan krevet razineVe"ina pljeva thickeners se ne odvijaju učinkovito z!og niza faktora, uključuju"i$

%. &hickener nema pouzdanu razinu krevet sučelje odašiljač koji "e raditi pod svimokoliša naseljuju uvjetima i ne utječe promjena gusto"e i

'. &hickener nema zamu"enja ili suspendirane krutine odašiljač koji "e pružiti povratnu informacijuoperatorom kontrolnoj so!i kako flocculent doziranje sustav radi.

#o ne koristi predajnik krevet razini koja je izvještačen mimo gusto"a, pljeva thickener krevet razini su op"enitotrčanje preniske u stožac thickener smanjenja gusto"e ispod granice koja se pumpa za pljeva !ranai crpne previše vode u pljeva.

(eto efekt je da pljeva !rana "e popuniti volumen !rže, a tu !olestan !iti dodatni trošakispumpavanje vode iz le)a pljeva !rane da se koncentriraju ili prep postrojenja.

Ve"ina pljeva thickeners koristiti automatsko doziranje flocculent sistem koji uzima uzorke hrane ivoda i o!avlja automatski jar rješavanje testa. &o je toliko važno gdje se više ugljena * rude vrste suo!ra)en kroz !iljka z!og različitih naseljavanja cijene i karakteristike. +e)utim, promatrača ili clarometers floc hrpa sustavi ne s vremena na vrijeme i pljeva thickener može promijenitivrlo !rzo da ne naseljavanju iz suspendirane tvari.

asno"a izlaz iz viši kraj pretvornici mogu alarm ovaj uvjet da operator u kontroliso!a. (eki čak imaju -spriječen sloj- izlaz koji se može koristiti u kontrolnoj petlji za flocdoziranje sustav kao !ack up. Korištenje odašiljača krevet razini omogu"it "e pljeva thickener !iti trčanjeautomatski u suradnji sa odašiljača ispod granice gusto"e i okretni moment od pojačala strugalicom.

&o se može$%. manjite troškove u kemikalija, širokog spektra floc doziranje * koagulant doziranje'. #ovratak troškovi ispumpavanje vode iz !rane pljeva/. manjiti pljeva na volumenu pljeva !rana i0. #ove"ajte kvalitetu i količinu vode se vratio na koncentrator s thickener.

Visoki po1ered sonara sonde2a1k je razvio visoku po1ered niz višestrukih polja kristalne sonara sonde koje sumogu"nosti operativnog i prodoran suspendirane tvari dati pouzdane performanse mjerenjateška gusto"a KR3V3& razin


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Each sonar transducer can perform two independent functions simultaneously. The second channel can

be used to provide clarity or simple turbidity output, or a second density interface as it measures, either a

second density in the interface column or the suspended solids levels between the BED level and the

face of the sonar transducer near the launder level.

The clarity output gives excellent process feedback information to the control room operators on how well

the flocculent dosing system is working. The ‘hindered layer’ or ‘interface layer’ gives feedback of how

well the settling characteristics are in the thickener and whether the broad spectrum flocculent is working

well, or whether coagulant maybe required.

If there are sufficient hours lost in production in the coal preparation plant, caused by tailing thickener

settling problems, then process plant managers may want to think about using a process control system

such as the ORCA Sonar.

These sorts of control systems can:

• Identify settling efficiencies caused by coal-type changes;

• Control the underflow pump to optimize the underflow density;

• Identify that the ‘clarometer’ or ‘observer’ instruments are working;


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vaki sonara sonde mogu o!avljati dva nezavisna funkcija istovremeno. 4rugi program može !iti korištena za pružanje jasno"a ili jednostavno zamu"enost izlaz, ili drugi gusto"e sučelja kao što je mjilidrugi gusto"e u stupcu sučelja ili suspendirane krutine razinama izme)u 5367 razine ilice sonara sonde u !lizini prati razinu.

asno"a izlaz daje odlične informacije procesa povratne operatori kontrolnoj so!i koliko do!roflocculent doziranje sustav radi. -priječen la8er- ili -sučelje la8er- daje povratnu informaciju o tome kakodo!ro naseljavanje karakteristike su u thickener i da li širok spektar flocculent radido!ro, ili da li možda koagulant potre!na.

7ko ima dovoljno sati izgu!ljeni u proizvodnju u tvornici ugljena pripremu, uzrokovane kraj signala thicrješavanje pro!lema, a zatim proces upravitelji postrojenja svi!anj ištanje to misliti o korištenju sustavakontrola procesakao što OR97 sonar.

Ove vrste sustava upravljanja mogu$: ;tvrditi rješavanje učinkovitost uzrokovane ugljen


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approximately 80 per cent of the broad spectrum flocculent, then coagulant was dosed to guarantee the

settling in the thickener. As the two densities again came together, with the hindered layer settling down

in the thickener again, the coagulant was stopped automatically. If the hindered layer rose away from the

compacted bed level and the clarometer did not change its dosing rate, the Sonar took over the flocculent

dosing control as a backup.

The high powered 3 crystal array transducer penetrated the suspended solids, even under poor settling

conditions. The clarity output could also be used, in the floc dosing control loop to automate this function

if the clarometer failed.

;spješna primjenaKupac je imao više vrsta ugljena koje su o!ra)ene kroz !iljni ugljen pripremi. (eki odugljen vrsta je rješavanje različitih karakteristika. &o je utjecalo na efikasnost i pljeva thickener -clarometer- instrument, koji testira naseljavanje stope u dolaznih feed do!ro, nije s vremena na vrijeme,što znači da floccing stopa promijenila i suspendirane krute tvari pove"ava, smanjuje kvalitetu povratak natrag u vodu prep !iljka.

2a1k pod uvjetom highupaljač gusto"a sučelje?.

Ova teža krevet izlazni nivo je !io korišten kao jedan od ulaznih petlje, za kontrolu pumpe ispod granice, tako dadošlo je zadržala ležaj du!ina u svim uvjetima taloženje, garantiraju"i optimizirana gusto"a !i"e pumpa za pljeva !rana.

Ometano sučelje razina je izlaz se koristi zajedno s teškim z!ijen krevet na raziniutvrditi promjene u naseljavanju uvjetima. 7ko dvije gusto"e rastali i clarometer je doziranje uoko @A posto od širokog spektra flocculent, onda koagulant !io doziran jamčitinaseljuju thickener. Kao dvije gusto"e ponovno došao zajedno sa slojem ometano taloženje do1nu thickener opet, koagulant je automatski zaustavljen. 7ko je spriječen sloj ruža daleko odz!ijen krevet razina i clarometer nije promijeniti svoje doziranje stopa, onar preuzela flocculentdoziranje kontrolu kao sigurnosna kopija.

#o1ered visok / sonde kristalno polje ušle suspendirane krutine, čak i pod sla!a taloženjeuvjetima. asno"a izlaz tako)er !i se mogla koristiti, u floc doziranje kontrolu petlje za automatiziranje ove funkako clarometer nije uspjelo


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Hawk - an ustralian !anufacturer

Hawk is an Australian manufacturer with a long experience from tough mining

environments. The products need to be durable and reliable and stand rain,

wind, dust, snow, sleet, foam or scum. Used in the mining industry for key

efficiencies with tailings dams and downstream processes, the Orca

equipment received two “Breakthrough Product of the Year” awards in USA

2008. Hawk manufacturers the largest range of sonar transducers to provide

optimized performance, for all bed level thickener applications e.g

concentrate thickeners etc.

2a1k je australski proizvo)ač sa dugogodišnjim iskustvom iz tvrd rudarstvookruženja. #roizvodi moraju !iti trajan i pouzdan te stajati kišu,vjetra, prašine, snijeg, susnježica, pjena ili šljam. Koristi se u rudarskoj industrključučinkovitosti s pljeva i nizvodno !rane procese, Orcaoprema do!io dva =#ro!oj #roduct of the Bear= nagrada u 74


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years of eperience, Hawk offers a record of success in a wide range of areas

including mining!mineral processing, water supply!waste water, bulk material handling and chemical. Hawk"s ongoing commitment aims to provide industry

leading technology and cost- effective solutions. #or more information about

Hawk, please visit www.hawkmeasure.com

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Optimized Thickeners in Coal Preparation Plants